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HSE Project Completion Report

PHASE 1

SGCP – RAK Project

Prepared By

Hafiz Hassan Shahzad

EHS Engineer – Weber Saint Gobain

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2. Project Scope

 Description of the work completed in Phase 1.

 Locations and departments involved.

 Duration of the project phase.

3. Key Activities

 List of key HSE-related activities:

o Risk assessments conducted.

o Inspections and audits performed.

o Training sessions provided.

o Safety drills or emergency response exercises.

4. Compliance with Standards and Regulations

 Saint-Gobain Standards:

o Detailed list of standards followed (e.g., EHS protocols, reporting requirements).

 UAE RAKEZ Regulations:

o Specific RAKEZ guidelines adhered to during the project phase.

5. Safety Performance Metrics

 Manpower and Manhours:

o Total manpower involved.

o Total manhours worked.

 Incident Statistics:
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o Number of reported incidents (near-misses, first-aid cases, etc.).

o Number of recordable incidents (if any).

 Observations and Corrective Actions:

o Total observations reported (TF1–TF5, SMATs).

o Number of corrective actions implemented.

6. Documents Procedures

 Site Safety Induction

 Toolbox Talks & Weekly HSE Meetings

 PTW System & Safe System of Work

7. Challenges Encountered

 Description of any major challenges faced during Phase 1.

 How these challenges were addressed or mitigated.

8. Annexures

 Copies of key documents:

o Inspection reports.

o Training attendance sheets.

o Toolbox Copies.

o Photographs of key HSE activities (if applicable).

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2. Project Scope

The Phase 1 of the RAK Plant Weber Project involved several critical activities aimed at

ensuring safe and efficient progress in line with Saint-Gobain Standards, UAE RAKEZ

regulations, and general HSE (Health, Safety, and Environment) protocols. The primary goal of

this phase was to complete significant structural, safety, and operational milestones necessary for

subsequent project phases.

This phase included site safety inductions, toolbox talks, excavation work, concrete pouring, fire

safety system installations, and the construction of key infrastructure elements such as boundary

walls, drainage systems, and storage areas. Additionally, HSE observations were rigorously

conducted, and compliance with PPE (Personal Protective Equipment) usage and work-at-height

regulations was strictly enforced. The scope also covered housekeeping, monitoring, and

ensuring that all relevant documentation was updated for audit purposes.

Description of the Work Completed in Phase 1

1. Safety Measures and Inductions: Throughout Phase 1, a key focus was placed on safety to

ensure the well-being of all workers. Daily site safety inductions were provided to both new and

existing workers, emphasizing adherence to PPE usage, safe systems of work, and compliance

with relevant regulations. Toolbox talks were conducted daily on various topics, including:

 Pedestrian safety and exclusion zones.

 Electrical safety and protection of electrical wiring, especially after rain.

 Work-at-height safety, grinding safety, and proper housekeeping.

 Ladder safety, scaffolding safety, and reinforcement of PPE compliance.

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 Fire safety and firefighting equipment usage.

Additionally, several inspections and observations were carried out by plant managers, HSE

officers, and external contractor’s safety officers to ensure full compliance with safety protocols.

2. Structural and Civil Works: The structural works included the erection and installation of

steel rebar and shutters. Concrete pouring activities were completed for the foundation of key

structures within and outside the warehouse. Specific tasks completed under structural and civil

works include:

 Installation of boundary walls and diesel tank storage areas.

 Construction of pump rooms, logistic rooms, and security rooms.

 Excavation and installation of manholes for drainage pipeline systems.

 Concrete base foundation work in the loading areas and external warehouse areas.

Significant progress was made in plastering and painting works. Primer paint was applied inside

the warehouse, and handrails and platforms were coated with dark yellow for better visibility and

safety.

3. Fire Safety System Installations: A major component of Phase 1 was the installation of fire

alarm and firefighting systems. These installations were critical for ensuring that the plant met

fire safety standards and could effectively handle potential fire hazards. The fire safety

installations included:

 Placement of fire extinguishers across key zones.

 Installation of fire hydrants and water supply systems.

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 Inspection and testing of fire alarm systems.

4. Electrical and Mechanical Installations: In addition to fire safety systems, electrical and

mechanical installations were also carried out during this phase. These included:

 Installation of electrical sockets and air conditioning units in office spaces.

 Securing gas cylinders with chain rings in designated areas.

 Ensuring safe anchoring of hooks for lifting operations.

5. Excavation and Earthworks: Excavation work was an integral part of Phase 1. Key

excavation activities included:

 Excavation around the cabin office and warehouse areas.

 Full barricading of the site to restrict unauthorized entry and ensure site safety.

 Leveling and clearing of the site for future construction activities.

6. Housekeeping and Site Maintenance: Housekeeping was continuously maintained

throughout Phase 1 to ensure a clean and hazard-free working environment. This included:

 Daily inspection and cleaning of work areas.

 Proper placement of tools and materials to avoid tripping hazards.

 Removal of waste and debris from work zones.

7. Documentation and Compliance: All relevant documentation related to safety inductions,

toolbox talks, PTWs (Permit to Work), and daily activity reports were updated and maintained

for future audits. PTWs were issued for high-risk activities such as hot work and work at height,

ensuring that all operations were conducted under strict supervision.

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Locations and Departments Involved

The work during Phase 1 was conducted across various key locations within the RAK Plant

Weber site, including:

1. Warehouse: The warehouse was a central location for multiple activities, including structural

work, fire safety installations, plastering, and painting. Concrete base foundations were laid, and

primer paint was applied to the internal walls.

2. Cabin Office and Surrounding Areas: Excavation work was carried out extensively around

the cabin office. This area was fully barricaded to prevent unauthorized access and ensure the

safety of personnel.

3. Loading Area: Concrete pouring and structural work were conducted in the loading area. This

included the installation of drainage systems and the construction of concrete bases for future

infrastructure.

4. Diesel Tank Storage Area: A dedicated area was designated for diesel tank storage. The tank

was successfully offloaded, and safety measures were implemented to secure the site.

5. Logistic Room, Security Room, and Pump Room: These rooms were constructed, and

installation activities were carried out to support the plant's operational needs. The pump room is

critical for firefighting systems, while the logistic and security rooms provide essential services

for site management.

Departments Involved:
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 HSE Department: Responsible for ensuring safety compliance, conducting inductions,

toolbox talks, and inspections.

 Civil Engineering Department: Overseeing structural and civil works, including

concrete pouring, excavation, and foundation work.

 Electrical and Mechanical Department: Handling electrical installations, mechanical

fittings, and air conditioning.

 Fire Safety Team: Supervising the installation and testing of firefighting and alarm

systems.

 Plant Management: Coordinating overall project activities and liaising with external

contractors.

 Contractors: Multiple contractors were engaged for specific tasks such as plastering,

scaffolding, and fire safety installations.

Duration of the Project Phase

Phase 1 of the HSE RAK Plant Weber Project commenced on November 4th, 2024, and

concluded on January 11, 2025, spanning a total duration of 54 days. During this period, daily

progress was tracked through detailed activity reports, ensuring that each task was completed on

time and in accordance with safety and quality standards.

The initial weeks focused on safety inductions, site clearance, and excavation work. As the phase

progressed, structural work, fire safety installations, and electrical/mechanical fittings were
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prioritized. The final weeks involved completing plastering and painting, securing diesel storage

areas, and ensuring that all documentation was up to date for audits.

Despite minor challenges posed by weather conditions, such as rain affecting electrical works,

the project team managed to maintain steady progress. Regular site visits by plant managers,

HSE officers, and external consultants helped in identifying potential risks and implementing

corrective actions promptly.

IMG1- Foundation of excavation of Filling Machine

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IMG2- Excavation for the Construction of Offices

IMG3- Excavation Work for Boundary Walls

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IMG4- Concrete Base Foundation for Filling Machine

IMG5- Excavation Work for Foundation of Fire Pump Room

IMG6- Installation & Maintenance of Silos through Manlift

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IMG 7 – Installation of Silos – Working at Height

IMG 8- Excavation Work for Office Construction

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IMG 9 – Excavation work for offices Constructions

IMG 10 – Excavation & Concrete Base Foundation for Weighing Bridge

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IMG 11 – Installation of Compressors

IMG 12 – Installation & Erection of Steel Concrete Rebar Structures

IMG 13 – Plastering of the Offices

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IMG 14 – Installation of Underground Diesel Storage Area

IMG 15 – Successful Installation of Warehouse Plant

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IMG 16- Erection of Combustible Room

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3. Key HSE-Related Activities: SGCP – RAK Project Overview

As the Safety Officer from Weber Saint-Gobain, my primary responsibility is to ensure that all

operations at the SGCP – RAK Project adhere strictly to the safety standards and protocols set by

Saint-Gobain. This report outlines the key HSE-related activities conducted during the project,

including risk assessments, inspections, training sessions, and safety drills or emergency

response exercises. These activities were essential in maintaining a safe work environment and

achieving compliance with both local regulations and Saint-Gobain’s internal safety policies.

1. Risk Assessments Conducted

At Saint-Gobain, risk assessments are conducted to proactively identify potential hazards and

implement appropriate controls to minimize risks. During the SGCP – RAK Project, risk

assessments were carried out for high-risk activities such as excavation, scaffolding, working at

height, and material handling operations. Each risk assessment was conducted in line with Saint-

Gobain’s risk management framework, which involves:

1. Identifying Hazards: Key hazards identified included trench collapses during excavation,

falling objects at height, and manual handling risks during warehouse operations.

2. Evaluating Risks: The likelihood and potential impact of each hazard were assessed to

prioritize risk mitigation measures.

3. Implementing Control Measures: Control measures such as installing proper barricades,

using appropriate PPE, and ensuring trained personnel were deployed on-site were promptly

executed.
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These risk assessments were reviewed periodically to ensure the continued effectiveness of the

control measures and to address any changes in site conditions.

2. Inspections and Audits Performed

In accordance with Saint-Gobain’s Safety Standards, routine inspections and audits were

conducted at critical stages of the SGCP – RAK Project. These inspections ensured compliance

with safety protocols related to PPE usage, equipment safety, scaffold stability, and vehicle

operations.

Inspections:

Focused on identifying non-conformities such as incomplete PPE compliance and expired

inspection tags on power tools.

Immediate corrective actions were taken to address identified issues, such as ensuring that all

tools and machinery had valid third-party inspection certificates.

3. Training Sessions Provided

Training is a cornerstone of Saint-Gobain’s Safety Policy, as it ensures that all personnel on-site

are well-informed about safety procedures and their responsibilities. During the SGCP – RAK

Project, multiple safety training sessions were conducted, covering topics such as:

Work at Height Safety: Focused on proper scaffold use, ladder safety, and fall protection

systems.

Emergency Preparedness: Workers were trained on evacuation procedures, assembly points,

and effective communication during emergencies.

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Manual Handling: Emphasized safe lifting techniques and the correct use of mechanical aids to

reduce the risk of musculoskeletal injuries.

These sessions were delivered using interactive methods to encourage active participation,

ensuring that workers fully understood the critical safety practices required on-site. Training

records were maintained for all participants in compliance with Saint-Gobain’s documentation

requirements.

4. Safety Drills or Emergency Response Exercises

Ensuring emergency preparedness is a key component of Saint-Gobain’s HSE framework.

During the SGCP – RAK Project, safety drills were conducted regularly to test the site’s

readiness in handling potential emergencies, including fire incidents, medical emergencies, and

adverse weather conditions.

Key objectives of these drills included:

Testing the effectiveness of emergency response plans and identifying any gaps.

Enhancing coordination among various teams, including contractors, supervisors, and the

emergency response team.

Improving response times and ensuring that workers were familiar with emergency procedures

such as evacuation routes and assembly points.

Post-drill debriefing sessions were held to gather feedback and implement necessary

improvements in emergency response strategies. This exercise greatly contributed to enhancing

overall site safety and readiness for real-life emergencies.

4. Compliance with Standards and Regulations

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Throughout Phase 1 of the SGCP – RAK Project, strict compliance with both Saint-Gobain

Standards and UAE RAKEZ Regulations was ensured to uphold safety, environmental, and

operational excellence. Adherence to these standards was critical for maintaining a safe work

environment, minimizing risks, and ensuring the project progressed without delays or incidents.

Saint-Gobain’s internal EHS (Environmental, Health, and Safety) protocols were at the core

of the compliance strategy. These protocols mandated daily toolbox talks, site safety inductions,

routine risk assessments, and proper documentation of all high-risk activities, including

excavation, scaffolding, and working at height. Reporting requirements were rigorously

followed, ensuring that all safety-related activities, inspections, and corrective actions were

documented and reviewed periodically. Saint-Gobain’s focus on continuous improvement was

evident through regular audits and inspections, which helped in identifying potential non-

conformities and promptly addressing them.

In addition to Saint-Gobain Standards, compliance with UAE RAKEZ (Ras Al Khaimah

Economic Zone) regulations was a top priority. RAKEZ guidelines for construction projects

emphasize worker safety, environmental protection, and proper waste management. During the

project, specific RAKEZ requirements adhered to included obtaining and maintaining valid work

permits for high-risk tasks, ensuring proper barricading around excavation sites, and providing

adequate firefighting equipment across key locations. Environmental regulations were met by

implementing waste segregation and ensuring that construction debris was regularly cleared from

the site.

By adhering to these comprehensive standards and regulations, the project not only maintained

safety but also ensured regulatory compliance, contributing to the successful completion of

Phase 1.
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EHS Meeting – No Smoking Policy at the Site

EHS Meeting – No Smoking Policy at the Site

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EHS Meeting – No Alcohol & Drugs Policy at the Site

EHS Meeting – Excavation & Work at Height Safety

EHS Meeting – Concrete Pouring Safety

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EHS Meeting – Site Compliance Rules and Regulations

EHS Meeting – Food Waste Management & Scaffolding Safety

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EHS Meeting – Hand Tools Safety

EHS Meeting – Power Tool & Hand Power Tools Safety

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EHS Meeting – Contractor’s Safety Management

4. EHS Performance Metrics

The Weekly HSE (Health, Safety, and Environment) performance metrics for the SGCP – RAK

Project provide an insightful summary of key safety activities conducted over several weeks. The

metrics are divided into two main categories: workforce-related data and safety compliance

statistics. Workforce-related data includes average manpower (number of workers) and total

manhours worked. These figures highlight the scale of the project, with manpower progressively

increasing from 14 workers in early November to 32 workers in early January, and manhours

worked rising from 924 to 2112 over the same period. This steady increase reflects the project’s

growth and the continuous efforts to ensure sufficient workforce allocation.

In parallel, the safety compliance metrics reveal a proactive approach toward risk management.

Safety observations ranged from 14 to 29 per week, ensuring that potential risks were promptly

identified and addressed. The number of corrective actions implemented closely matched the

safety observations, demonstrating the team’s commitment to closing safety gaps efficiently.
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Recordable incidents remained at zero throughout the period, underscoring the effectiveness of

safety measures in preventing injuries or accidents on-site.

Further analysis shows that near-miss reports and hazardous conditions identified were carefully

documented and monitored. While near-miss reports increased in certain weeks, hazardous

conditions were regularly tracked, with a peak of 20 identified conditions being addressed

promptly. The compliance with permit-to-work (PTW) and PPE (Personal Protective Equipment)

requirements was maintained daily, ensuring that all high-risk activities were carried out safely.

Overall, the weekly HSE metrics reflect a well-managed project with a strong emphasis on safety

and risk mitigation.

Avg.
Manpow
er
(Number Avg. Safety Correcti
of Manhou Observatio Recordab ve
Workers rs ns le Actions Permit to Work
Week ) Worked Conducted Incidents Closed (PTW) Compliance
04/11/2024 -
09/11/2024 14 924 16 0 16 Daily
11/11/2024 -
16/11/2024 20 1320 15 0 15 Daily
18/11/2024 -
23/11/2024 24 1584 21 0 21 Daily
25/11/2024 -
30/11/2024 25 1650 29 0 29 Daily
02/12/2024 -
07/12/2024 25 1375 14 0 14 Daily
09/12/2024 -
14/12/2024 27 1450 18 0 17 Daily
16/12/2024 -
21/12/2024 28 1848 21 0 21 Daily
23/12/2024 -
28/12/2024 27 1782 14 0 14 Daily
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30/12/2024 -
04/01/2025 30 2050 22 0 20 Daily
06/01/2025 -
11/01/2025 32 2112 25 0 35 Daily

Table 1- EHS Statistics

Number

of Number of

Critical Critical

Risks Risks Hazardous

PPE Identifie Eliminate Near Miss Conditions

Week Compliance d d Reports Identified

04/11/2024 -

09/11/2024 Daily 0 0 0 11

11/11/2024 -

16/11/2024 Daily 3 3 0 10

18/11/2024 -

23/11/2024 Daily 2 2 0 14

25/11/2024 -

30/11/2024 Daily 2 2 20 20

02/12/2024 -

07/12/2024 Daily 2 2 11 11

09/12/2024 -

14/12/2024 Daily 1 1 10 12

16/12/2024 - Daily 1 1 14 14
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21/12/2024

23/12/2024 -

28/12/2024 Daily 0 0 10 15

30/12/2024 -

04/01/2025 Daily 1 1 12 13

06/01/2025 -

11/01/2025 Daily 0 0 35 35

Table 2 – EHS Statistics

6. Documents Procedures

Site Safety Induction:

The site safety induction procedure ensures that all personnel entering the site are fully aware of

the safety protocols, hazards, and Saint-Gobain’s HSE standards. Upon arrival at the site,

security personnel first coordinate with the HSE Officer to verify the credentials and ensure that

the workers are registered. The HSE Officer then conducts the site safety induction, which

includes information on exclusion zones, emergency procedures, use of PPE, and Saint-Gobain’s

core safety values. After the induction is completed, the workers are mobilized to their respective

work areas. Records of all inductions are maintained for audit purposes.

Toolbox Talks & Weekly HSE Meetings:

Toolbox talks are conducted daily by supervisors or HSE Officers before the start of work. These

talks focus on specific tasks and associated risks, such as working at height, manual handling,

and electrical safety. Attendance is recorded, and key discussion points are documented.

In addition to daily toolbox talks, a weekly HSE meeting is held every Friday from 12:00 to
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12:30 PM. This meeting involves HSE Officers, supervisors, and contractor representatives to

review the past week’s safety performance, discuss any incidents or near misses, and plan for

upcoming high-risk activities. Minutes of the meeting are documented and shared with relevant

stakeholders.

PTW System & Safe System of Work:

A Permit to Work (PTW) system is strictly maintained for high-risk activities, including

excavation, work at height, and hot work. PTWs are issued after a thorough risk assessment is

conducted, and control measures are verified. The HSE Officer ensures that all PTWs are valid,

displayed at the work location, and renewed as required. Safe systems of work are enforced, and

regular inspections are conducted to ensure adherence to PTW requirements.

7. Challenges Encountered

During Phase 1 of the SGCP – RAK Project, several significant challenges were encountered in

ensuring compliance with safety standards, particularly with contractors who were initially

unaware of essential safety protocols. As the Safety Officer, I observed a lack of understanding

and awareness regarding critical safety practices among the workforce provided by the

contractors. This posed immediate risks to project activities, necessitating urgent intervention

and corrective measures.

One of the primary challenges was ensuring proper adherence to exclusion zones. Many workers

were unfamiliar with the concept of restricted areas and the importance of maintaining safe

distances from high-risk operations. Additionally, scaffolding safety was another major concern.

Contractors often attempted to use substandard scaffolding materials or unsafe practices, which

increased the risk of falls and injuries. The widespread use of wooden ladders, which did not
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meet safety standards, further complicated the situation, requiring us to implement strict control

measures and alternative solutions.

Another pressing issue was the insufficient use of task-specific Personal Protective Equipment

(PPE). Contractors frequently failed to provide appropriate PPE, such as cut-resistant gloves and

impact-resistant gloves, exposing workers to unnecessary hazards. Beyond safety awareness, we

also had to educate contractors on Saint-Gobain’s core values, safety procedures, and the correct

process for conducting safety inductions.

We conducted intensive daily safety awareness sessions and toolbox talks to mitigate these

challenges, focusing on high-risk tasks and SG safety procedures. Regular inspections and audits

ensured continuous compliance, while corrective actions were swiftly implemented. This

approach significantly improved safety awareness and performance on-site, contributing to the

overall success of Phase 1.